US20060047049A1 - Flame retardant compositions for flammable plastics and flame retarded plastic compositions containing the same - Google Patents

Flame retardant compositions for flammable plastics and flame retarded plastic compositions containing the same Download PDF

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Publication number
US20060047049A1
US20060047049A1 US11/216,066 US21606605A US2006047049A1 US 20060047049 A1 US20060047049 A1 US 20060047049A1 US 21606605 A US21606605 A US 21606605A US 2006047049 A1 US2006047049 A1 US 2006047049A1
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flame retardant
flame
dimethyl
parts
weight
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Hideaki Onishi
Makoto Teramoto
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DKS Co Ltd
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Assigned to DAI -ICHI F R CO., LTD. reassignment DAI -ICHI F R CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ONISHI, HIDEAKI, TERAMOTO, MAKOTO
Publication of US20060047049A1 publication Critical patent/US20060047049A1/en
Assigned to DAI-ICHI KOGYO SEIYAKU CO., LTD. reassignment DAI-ICHI KOGYO SEIYAKU CO., LTD. MERGER (SEE DOCUMENT FOR DETAILS). Assignors: DAI-ICHI F R CO., LTD.
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
    • C08K5/0066—Flame-proofing or flame-retarding additives
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/0091—Complexes with metal-heteroatom-bonds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/01—Hydrocarbons
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/02—Halogenated hydrocarbons

Definitions

  • the present invention relates to a flame retardant composition for flammable plastics. It also relates to a flame retarded plastic composition containing said flame retardant composition.
  • plastics or synthetic resins are used as parts or components of many electric and electronic devices and apparatus by virtue of their high insulating performance, high water resistance, high moldability, adequate mechanical strength, etc. They also find use in packaging materials and construction materials. However, the most of plastics are flammable and hence flame retarded for use in many applications for safety reasons. The level of flame retardancy required for plastic articles has been standardized in many applications and is becoming more stringent in recent years.
  • plastics are rendered flame retardant by incorporating a brominated flame retardant and antimony trioxide into plastics.
  • a brominated flame retardant and antimony trioxide concern has arisen about carcinogenic dioxines and other compounds which are produced when combusting waste plastic articles containing the brominated flame retardant.
  • Attempts have been made to replace the brominated flame retardant with halogen-free flame retardants such as phosphate esters or ammonium polyphosphate.
  • halogen-free flame retardants such as phosphate esters or ammonium polyphosphate.
  • the use of these halogen-free flame retardants in an amount sufficient to achieve a desired flame retardancy level necessarily compromises other requisite properties such as moldability and strength properties because the halogen-free flame retardants are far less effective than the brominate flame retardants.
  • a need exists for a flame retardant composition which enables the amount of brominated flame retardants needed for achieving a desired level of flame retardancy in plastic articles to be significantly reduced compared to the brominated flame retardant alone.
  • Such a composition would be advantageous not only for environmental reasons but it enables molding scraps of flame retarded plastics to be recycled because of low contents of brominate flame retardants.
  • thermoplastic polymers may be rendered flame retardant by incorporating a free-radical generator such as 2,3-dimethyl-2,3-diphenylbutane or dicumylperoxide.
  • the free-radical generator selectively breaks the main chain of polymers and increases the flowability of molten-polymers to help the self-extinguishability thereof.
  • a free-radical generator selected from the group consisting of 2,3-dimethyl-2,3-diphenylbutone and its homologs;
  • said free-radical initiator is 2,3-dimethyl-2,3-diphenylbutane (DMDPB), 3,4-dimethyl-3,4-diphenylhexane, 4,5-dimethyl-4,5-diphenyloctane, 3,4-diethyl-3,4-diphenylhexane, 4,5-diethyl-4,5-diphenyloctane, 2,3-dimethyl-2,3-di-p-tolylbutane or 3,4-dimethyl-3,4-di-p-tolylhexane; while said metal is Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pd or Pt.
  • DMDPB 2,3-dimethyl-2,3-diphenylbutane
  • DMDPB 2,3-dimethyl-3,4-diphenylhexane
  • 4,5-dimethyl-4,5-diphenyloctane 3,4-diethy
  • the flame retardant composition comprises
  • the present invention provides a flame retarded plastic composition
  • a flame retarded plastic composition comprising a flammable plastic material and the flame retardant composition of the present invention in an amount corresponding to 0.5 to 25 parts by weight of said brominated flame retardant per 100 parts by weight of said flammable plastic material.
  • the amount of brominated flame retardants needed to achieve a desired flame retardancy level may be significantly saved compared to that of the brominated flame retardant alone.
  • the brominated flame retardant By virtue of reduced quantity of the brominated flame retardant, many beneficial properties of plastic materials such as molding and mechanical properties may be less compromised and the environmental concern may be ameliorated.
  • scraps produced in association with processing may be recycled.
  • the present invention utilizes a synergism of both of the free-radical generator and the phtolocyanine or naphthalocyanic complex to save the brominated flame retardant.
  • 2,3-dimethyl-2,3-diphenylbutane or its homologs refers to 1,2-diphenyl-1,1,2,2-tetraalkylethane and derivatives thereof having one or more alkyl substituents on one or more benzene rings in which each alkyl contains 1 to 6 carbon atoms.
  • These compounds otherwise called free-radical initiator, are known to generate a free radical upon heating to a temperature above the process temperature of most of plastic materials. Therefore, they remain intact during the processing such as extrusion injection molding, compression molding, hot press lamination or the like.
  • Copper phthalocyanine complexe such as phthalocyanine blue and phthalocyanine green are known as a thermally stable pigment and used in the production of colored plastic articles.
  • U.S. Pat. No. 3,825,520 teaches that Fe, Cu, Mn, V and Co phthalocyanines may reduce smoke when incorporating into a styrene polymer in conjunction with octabromobiphenyl fire-retardant.
  • a metal phthalocyanine or naphthalocyanine is effective to save a brominated flame retardant when incorporating in conjuntion with a free-radical generator into flammable plastic materials.
  • Brominated flame retardants are well known in the art. Non-limitative examples are as follows.
  • Brominated alycyclic hydrocarbons hexabromocyclododecane (HBCD), tetrabromocyclooctane (TBCO), monochloropentabromocyclohexane, etc.,
  • Brominated aromatic hydrocarbons pentabromotoluene, hexabromobenzene, decabromodiphenylethane, brominated polystyrene, octabromotrimethylindane, etc.
  • Brominated phenyl ethers decabromodiphenyl ether, octabromodiphenyl ether, hexabromodiphenyl ether, bis(tribromophenoxy)ethane, bis(pentabromophenoxy)ethane, poly(2,6-dibromophenyleneoxide), etc.,
  • Brominated bisphenols and derivatives thereof tetrabromobisphenol A, tetrabromobisphenol S, tetrabromobisphenol F, tetrabromobisphenol A bis(2,3-dibromopropyl)ether, tertrabromobisphenol S bis(2,3-dibromopropyl)ether, tetrabromobisphenol F bis(2, 3-dibromopropyl)ether, tetrabromobisphenol A bis(2,3-dibromoisobutyl)ether, tetrabromobisphenol S bis(2,3-dibromoisobutyl)ether, tetrabromobisphenol F bis(2,3-dibromoisobutyl)ether, tetrabromobisphenol A diallyl ether, tetrabromobisphenol S diallyl ether, tetrabromobisphenol F diallyl ether, tetrabrom
  • Brominated isocyanurates tri(2,3-dibromopropyl)isocyanurate, tri(2,3-dibromosiobutyl)isocyanurate, etc.
  • brominated flame retardants tetrabromophthalic anhydride, brominated. polycarbonate, brominated epoxy resins, poly(pentabromobenzyl acrylate), ethylenebis(tetrabromophthalimide), 2,4,6-tris(2,4,6-tribromophenoxy)-1,3,5-triazine, tris(tribromoneopentyl)phosphate, etc.,
  • the free-radical generator used in the present invention is 2,3-dimethyl-2,3-diphenylbutane or a homolog thereof.
  • homologs include 3,4-dimethyl-3,4-diphenylhexane, 4,5-dimethyl-4,5-diphenyloctane, 2,3-dimethyl-2,3-di-p-tolylbutane and 3,4-dimethyl-3,4-di-p-tolylhexane.
  • 2,3-Dimethyl-2,3-diphenylbutane(dicumene) is preferable.
  • the metal phthalocyanine complex and the naphthalocyanine complex used in the present invention possesses the same or analogous ligand structure as the copper phthalocyanine pigment.
  • their central atom is chosen from a metal element of groups 7 to 10 of the IUPAC periodic chart in place of copper.
  • the central atom is Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni or Pt. Co or Fe is particularly preferable.
  • the central atom may also be coordinated with a halogen ion, typically chloride ion.
  • the phthalocyanine or naphthalocyanine ligand may have a substituent such as Cl, Br, alkyl, alkoxy, carboxyl or amino on the benzene ring.
  • Phthalocyanine complexes and naphthalocyanine complexes having a central metal other than the above-mentioned metal species such as Cu, Ti, Zn, V or Cr have no or little effect to save the brominated flame retardant when use alone or in conjuction with the free-radical generator.
  • the ratio of (b):(c) in the flame retardant composition is 99:1 to 1:99, preferably 90:10 to 10:90, most preferably 75:25 to 25:75 by weight.
  • the proportion of the sum of (b) +(c) is 0.01 to 50, preferably 0.1 to 30 and most preferably 0.2 to 20 parts by weight per 100 parts by weight of (a).
  • the flame retardant composition of the present invention is incorporated into flammable plastic materials.
  • the quantity of the composition to be incorporated may vary depending on the desired flame retardancy, the nature of particular components (a), (b) and (c) and the presence of auxiliary flame retardants such as antimony trioxide and/or halogen-free flame retardants such as phosphate esters. This quantity ranges generally from 0.5 to 25, preferably from 1.0 to 15 by weight in terms of (a) per 100 parts of weight of the flammable plastic material. As stated above, this quantity should not be excessive as far as the desired flame retardancy may be achieved.
  • the flammable plastic materials to be rendered flame retardant are mostly thermoplastics.
  • Non-limitative examples thereof include polystyrene, high impact polystyrene (HI-PS), styrene-butadiene copolymer, styrene-acrylonitrile copolymers, acrylonitrile-butadiene-styrene copolymer (ABS), polyethylene tetraphthalate (PET), polybutylene terephthalate, liquid crystalline polyester, polycarbonate, polyamide, polyphenyleneoxide, modified polyphenyleneoxide, polyphenylenesulfide, polyacetal, polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-propylene copolymer, ethylene-1-butene copolymer, ethylene-propylene-non-conjugated diene copolymer, ethylene-ethyl acrylate copolymer, ethylene-glycidy
  • Polystyrene, HI-PS, polypropylene, ABS, polycarbonate and polyamide are typical examples of plastics used for fabricating plastic articles in large quantities.
  • the flame retardant composition of the present invention finds use in thermosetting plastics or resins.
  • the compostion may be incorporated into laminates of phenol, epoxy or unsaturated polyester resin having paper or glass fiber substrates.
  • a portion of the brominated flame retadant (a) in the flame retardant composition may be replaced by a halogen-free phosphorus-based flame retardant to further save the brominate flame retardant (a) as far as the desired flame retardancy is achieved.
  • Non-limitative examples of the phosphorus-based flame retardants include triphenyl phosphate, tricreyl phosphate, trixylenyl phosphate, diphenylcresyl phosphate, trixylenyl phosphate, resorcinol-bis(diphenyl)phosphate, bisphenol A-bis(diphenyl)phosphate, resorcinol-bis(dicresyl) phosphate, bisphenol A-bis(dicresyl)phosphate, resorcinol-bis(di-2,6-xylenyl)phosphate, bisphenol A-bis(2,6-xylenyl)phosphate, phenoxyphosphazene, methylphenoxyphosphazene, xylenoxyphosphazene, methoxyphosphazene, ethoxyphosphazene, proxyphosphazene, melamine polyphosphate, and ammonium polyphosphate.
  • the flame retarded plastic composition may optionally comprise other conventional additives.
  • One such optional additive is an auxiliary antioxidant such as antimony trioxide, antimony pentaoxide, tin oxide, zinc stannate, zinc stannate hydroxide, molybdenum oxide, ammonium molybdate, zirconium oxide, zirconium hydroxide, zinc borate, zinc metaborate or barium metaborate.
  • Antimony trioxide is most preferable.
  • the quantity of the auxiliary flame retardant, if incorporate, may range from 0.1 to 10 parts by weight per 100 parts by weight of the flammable plastic material.
  • Examples of other conventional additives include heat stabilizers, antioxidants, UV absorbers, UV stabilizers, impact strength enhancers, pigments, fillers, lubricants, dripp retardants, crystalline nuclei agents, mold release agents, antioxidants and compatibilizers. These conventional additives are well known in the plastic processing art and details thereof may be found in many handbooks relating to the plastic processing technology.
  • a blowing agent is incorporated in the flame retarded plastic composition optionally in conjuction with a foam nuclei agent or foam conditioning agent.
  • the blowing agent include volatile organic blowing agents such as propane, butane, pentane, hexane, 1-chloro-1,1-difluoroethane, monochlorodifluoromethane, monochloro-1,2,2,2-tetrafluoroethane, 1,1-difluoroethane, 1,1,1,2-tetrafluoroethane or 1,1,3,3,3-pentafluoropropane; inorganic blowing agents such as water, nitrogen or carbon dioxide; and chemical blowing agents such as azo compounds.
  • foam nuclei agents or foam conditioning agents are talc and bentonite.
  • the quantity of the blowing agent may vary depending on the desired properties of foams and generally ranges between 0.005 to 0.7 mole/100 g of the plastic material.
  • the flame retarded plastic composition of the present invention may be prepared by the known method.
  • the flame retardant composition and optional additives are melt-blended using known apparatus such as biaxial extruders, Barnbury mixer, laboplastomills or hot roll mills and then molded into a desired shape by extruding, injection molding or compression molding.
  • the flame retardant composition and the optional additives may be blended together or separately.
  • the blowing agent may be directly injected into the molten plastic composition in the extruder.
  • plastic beads containing the flame retardant and optional additives may be impregnated with a liquid blowing agent such as pentane followed by heating the beads in a mold with steam.
  • thermosetting plastics such as phenol resin
  • the flame retardant and optional additives may be incorporated into oligo-condensates or varnish in conjunction with a curing catalyst, if needed, and the mixture may be cast or lamination molded.
  • A-1 High impact polystyrene available from Toyo Styrene Co., Ltd. under the name of TOYO STYROL H450
  • A-2 High impact polystyrene available from Toyo Styrene Co., Ltd. under the name of TOYO STYROL H650
  • A-3 Polypropylene available from Sumitomo Chemical Co., Ltd. under the name of SUMITOMO NOBLEN Y101S.
  • A-4 A 70:30 blend of polycarbonate available from Idemitsu Petrochemical Co., Ltd. under the name of TARFLON A 2000 and ABS available Toray Industries, Inc. under the name of TOYOLAC
  • A-5 Polyamide available from Asahi Kasei Corporation under the name of REONA 1300S
  • A-6 High density polyethylene available from Idemitsu Petrochemical Co., Ltd. under the name of IDEMITSU HD130J
  • A-7 Polystyrene available from Toyo Styrene Co., Ltd. under the name of TOYO STYROL G220
  • test specimen was 125 mm in length, 12.5 mm in width and 3.2 mm in thickness. NR indicates not rating.
  • oxygen index (LOI) was determined according to JIS K 7201 standard test.
  • the pellets for making test specimens were aged in an oven kept at a constant temperature of 80° C. and at a constant himidity of 95% RH for one week.
  • the aged pellets were extruded again into pellets and injection molded into the test specimens under the same conditions as above.
  • EXAMPLE COMP EXAMPLE Formulation(parts) & Test results 10 11 12 13 10 11 12 Plastics A-4 100 100 100 100 100 100 100 100 100 100 Brominated flame retardant B-5 B-6 B-7 B-5 B-5 B-6 B-7 6.0 5.5 5.0 7.0 6.0 5.5 5.0 Radical generator C 0.475 0.040 0.3 0.03 — 0.025 0.5 Phthalocyanine/naphthalocyanine D-1 D-2 D-3 D-4 D-1 D-5 — complex 0.025 0.475 0.3 0.03 0.5 0.475 — Heat stabilizer E-1 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 Antioxidant E-2 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 Antimony trioxide 0.5 0.5 0.5 1.0 0.5 0.5 0.5 Flame retardancy, UL-94 V-0 V-0 V-0 V-0 V-2 NR V-2 Flexural strength, Mpa 78 70 73 74 78
  • the flame retardancy of the formulations of Examples 1-20 is enhanced compared to that of the formulations of Comparative Examples 1-19 by incorporating the brominated flame retardant into the plastic material in conjuction with the radical generator and the phthalocyanine/naphthalocyanine complex with a metal of groups 7-10 of the periodic chart.
  • various materials excluding the blowing agent were fed to a two stage tandem extruder.
  • the materials are heat blended in the first stage extruder having an inner diameter of 65 mm and then extruded to the second stage extruder having an inner diameter of 90 mm.
  • a predetermined amount of the blowing agent was injected under pressure into the extrudate through a separate line at the forward end of the first stage extruder.
  • the extrudate from the first stage extruder was cooled to 120° C. in the second stage extruder and extruded through a die into a ribbon having a width of 45 mm and a thickness of 2.5 mm.
  • the state of the resulting extrudate was visually evaluated in accordance with the following criteria.
  • a foamed extrudate free of crackes or voids is stably obtained.
  • the foamed extrudate includes a number of cracks or voids, or stable extrusion is not possible due to blowing of gas from the die.
  • Oxygen index (LOI) was determined according to JIS K 7201 standard test.
  • the foamed extrudate produced in the initial extruding was crashed and aged in an oven kept at a constant temperature of 80° C. and at a constant humidity of at 95% RH for one week.
  • the aged particles were blow-extruded again under the same conditions as above.
  • the recycled extrudate was tested for the state, the oxygen index and self-extinguishability.
  • the recycling test was not conducted for the extrudates of Comparative Examples. The results are shown in Tables 7-8 below.
  • the foamed extrudates of Examples 21-26 exhibited satisfactory results in the flame retardancy and the foamed state.
  • the foamed extrudates of Comparative Examples 20-23 were not self-extinguishable although the foamed state was good.
  • the foamed extrudate of Comparative Example 23 was self-extinguishable because of increased amount of brominated flame retardant in conjuction with a phosphate ester but observed a number of cracks and scorching.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Fireproofing Substances (AREA)
US11/216,066 2004-09-01 2005-09-01 Flame retardant compositions for flammable plastics and flame retarded plastic compositions containing the same Abandoned US20060047049A1 (en)

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JP2004-254343 2004-09-01
JP2004254343A JP4395840B2 (ja) 2004-09-01 2004-09-01 プラスチック用臭素系難燃剤組成物

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US (1) US20060047049A1 (zh)
EP (1) EP1632525B1 (zh)
JP (1) JP4395840B2 (zh)
CN (1) CN100406512C (zh)
AT (1) ATE399814T1 (zh)
DE (1) DE602005007814D1 (zh)
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WO2012168261A1 (en) * 2011-06-09 2012-12-13 Akzo Nobel Chemicals International B.V. Solid composition comprising a radical forming compound and a flame retardant
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